无锡科技职业学院11级斜插坐毕业设计

毕业设计（论文）报告

题 目 斜插座注塑模具结构设计与制造

系 别 中德机电学院 专 业 模具设计与制造 班 级 模具1101 学生姓名 *** 学 号 指导教师

2014年 4月

无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

斜插座塑模具结构设计与制造

摘要：本文介绍的是关于一个筒形带斜管零件的注塑模具设计方案及说明。零

件结构比较简单，精度要求和尺寸公差没有苛刻的要求，但内部特征结构比较复杂，需要斜抽芯结构进行脱模。考虑到生产成本，顾本模具采用一模两腔的方案进行设计。塑件高度尺寸一般，根据塑件结构特征决定采用点浇口双分型面机构进行设计。推出系统采用斜推管推出，采用复位杆复位及导向作用，由于存在斜抽芯，因此模具采用弹簧预复位。排气系统利用分型面的间隙与型芯与型腔之间的间隙进行排气。

关键词：注塑模、一模两腔、斜抽芯、推管推出

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

The Xiechazuo Injection mold design

Abstract：This article describes about a cylindrical tube with oblique injection mold

design parts and instructions. Part structure is relatively simple, precision and dimensional tolerances no demanding, but the internal features of the structure is more complex, the need oblique core pulling structure mold. Taking into account the cost of production, Gu the mold using a two-cavity mold program design. Plastic height dimension in general, based on structural characteristics determine the design of plastic parts using point gate double parting surface body. Launch system using oblique push tube launched, using the reset lever reset and guiding role, due to the presence of oblique core pulling, so the mold with spring pre-reset. Exhaust system using sub-surface clearance gap between the core and the cavity is exhausted.

Key Words: Injection mold a mold two chambers

inclined core pulling pushing tube launched

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

目录

前言 ································································································································· 1 第一章 方案论证 ··········································································································· 2

1.1 塑件的结构工艺性分析 ··················································································· 2 1.2 成形工艺分析 ··································································································· 2 1.3 生产规模 ··········································································································· 3 第二章 斜插座注塑模结构设计 ··················································································· 4

2.1 成型零件设计 ··································································································· 4

2.1.1 分型面位置的确定 ················································································· 4 2.1.2 成型零件结构分析 ················································································· 4 2.1.3 成型零件材料的选用 ············································································· 5 2.1.4 成型零件的结构设计 ············································································· 5

2.1.4.1 定模结构设计 ··············································································· 5 2.1.4.2 动模和型芯结构设计 ··································································· 5 2.1.5 成型零件工作尺寸计算 ········································································· 6

2.1.5.1 型腔径向尺寸 ··············································································· 6 2.1.5.2 型腔深度尺寸 ············································································ 7 2.1.5.3 型芯径向尺寸 ··············································································· 8 2.1.5.4 型芯高度尺寸 ··············································································· 8

2.2 浇注系统设计 ··································································································· 9

2.2.1 主流道的设计 ······················································································· 10 2.2.2 分流道的布置形式 ··············································································· 11 2.2.3 分流道的形状 ······················································································· 12 2.3推出机构的设计 ······························································································ 12

2.3.1 梯形推板的推动原理和草图 ······························································· 12 2.3.2 梯形推板的设计要求 ··········································································· 12 2.4 排气系统 ········································································································· 13 2.5 冷却系统的设计 ····························································································· 13

2.5.1 冷却管道直径 ······················································································· 13

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

2.5.2冷却水道的位置 ···················································································· 13 2.6 模架与注射机的选择 ····················································································· 14

2.6.1 模架的选择 ··························································································· 14 2.6.2 注塑机的选择 ······················································································· 14

2.6.2.1 注射量的计算 ············································································· 14 2.6.2.3 锁模力的计算 ············································································· 14 2.6.3 注塑机参数的校核 ··············································································· 15

2.6.3.1 注射压力的校核 ········································································· 15 2.6.3.2 锁模力的校核 ············································································· 15 2.6.3.3 模具外形尺寸校核 ····································································· 15 2.6.3.4 喷嘴尺寸及定位圈尺寸校核 ····················································· 16 2.6.3.5 开模行程的校核 ········································································· 16

2.7 模具结构草图 ································································································· 17

2.7.1 定模结构图 ··························································································· 17 2.7.2 动膜结构图 ··························································································· 17 2.7.3 模具总结构图 ······················································································· 18 2.8 注射模动作过程分析 ····················································································· 18 第三章 成型零件加工工艺 ························································································· 19

3.1 加工路线 ········································································································· 19 3.2 数控编程 ········································································································· 19

3.2.1 加工工艺确定 ······················································································· 19 3.2.2 打开工件 ······························································································· 19 3.2.3 坐标系转换 ··························································································· 19 3.2.4 创建数控编程操作 ··············································································· 20 3.2.5 创建铣刀 ······························································································· 20 5.2.6 平面铣 ··································································································· 20 3.2.7 设置参数 ··································································································i 3.2.8 粗加工型芯 ··························································································· 23 3.2.9 创建侧面精加工操作 ··········································································· 23

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

3.2.10 创建平面精加工操作 ········································································· 24 3.2.11 后置处理 ····························································································· 24 3.3 程序清单 ·································································································· 25

第四章 结束语 ············································································································· 28

4.1 总结 ················································································································· 28 4.2 创新点 ············································································································· 28 致谢 ······························································································································· 29 参考文献 ······················································································································· 30

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

前言

塑料是以树脂为主要成分的高分子有机化合物，树脂可分为天然树脂和合成树脂两大类，塑料大多数采用合成树脂。各种合成树脂都是将低分子化合物的单体通过合成的方法生产出的高分子化合物，一般相对分子质量都大于1万，有的甚至可达百万级。在一定的温度和压力下，塑料具有可塑性，可以利用模具将其成型为具有一定几何形状和尺寸精度的塑料制件。

塑料是20世纪发展起来的新兴材料，塑料的兴起必定推动塑料成型制品的广泛应用特别是在电子玩具、电子仪表、电器设备、通信工具、生活用品等方面获得大量应用。塑料成型制品是以塑料为主要结构材料经成型加工获得的制品又称塑料制件简称塑件。塑料成型是将各种形态的塑料原料粉状、粒状、熔体或分散体熔融塑化或加热达到要求的塑性状态在一压力下经过要求形状模具或充填到要求形状模具模腔内待冷却定型后获得要求形状、尺寸及性能塑料制件的生产过程。注塑模具是塑料成型加工中的工艺装备。它是利用其特定形状去复制成型或复制加工具有一定形状和尺寸制件的工具。塑料模具一般可多次使用适应大批量生产。因此注塑是现代工业生产中重要的工艺装备。

本文主要介绍的是对于一个需要斜抽芯的注塑件注塑模具的设计方案。在本文中，我将和大家一起研究这个模具的流到、分型、脱模等机构的设计。

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

第一章 方案论证

1.1 塑件的结构工艺性分析

塑件是一圆筒形带斜插管零件，如图1.1所示。塑件是一个不规则旋转体结构，内部特征结构比较复杂。塑件的壁厚不均匀，圆台部分壁厚和斜插管的壁厚是不一样的。塑件质量一般，材料为聚碳酸酯，该种塑料流动性好，满足注射成型工艺。该塑件尺寸没有特殊的要求，所以生产工艺较简单，主要需要考虑的是模具生产中如何做到自动脱模，减少人工。

图1.1 塑件图

1.2 成形工艺分析

聚碳酸酯塑料，英文名称:Polycarbonate,简称PC。

1、基本特征：聚碳酸酯是一种无定型、无臭、无毒、高度透明的无色或微黄色热塑性工程塑料，具有优良的物理机械性能，尤其是耐冲击性优异，拉伸强度、弯曲强度、压缩强度高；蠕变性小，尺寸稳定。

2、主要用途：在机械方面主要用于制作各种齿轮、涡轮、齿条、凸轮、芯轴、轴承、铰链、螺母、灯罩、节流阀、各种外壳、冷却装置零件等；在电气方面，

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

用于制作机电零件、电话交换器零件、仪表壳、接线板等。聚碳酸酯还可以制作照明灯、高温透镜、视孔镜、防护玻璃灯光学零件。

3、成型特点：聚碳酸酯虽然吸水性小，但高温时对水分比较敏感，熔融温度高，熔融粘度大，流动性差。

1.3 生产规模

该塑件精度要求不高，并且结构还算简单，又是大批量生产，双分型机构，考虑到模具制造费用及模具外形尺寸，初定为一模两腔的模具形式。

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

第二章 斜插座注塑模结构设计

2.1 成型零件设计

成型零件指的便是注塑模具闭合时,起到固定成型塑料制品型腔的零件。它主要包括凹模、凸模、型芯。成型零件在生产过程中会承受高温高压塑料熔体的冲击和摩擦。在生产过程中成型零件的尺寸精度、表面质量及其材料的稳定性越高，注塑产品的质量就会越高。成型零件的强度和刚度要求需要达到一定的条件，因为成型零件在合模保压阶段时会承受很高的型腔压力。影响模具工作寿命的主要因素有，成型零件的材料、热处理和工工艺性以及结构设计。

2.1.1 分型面位置的确定

在选择分型面时应该根据选择分型面的原则进行选择，要不影响塑件的外观要求并能保证成型后能顺利取出塑件。根据塑件的技术要求，外表面无明显缺陷，因此模具分型面设置在塑件的最大轮廓处，如下图2.1所示：

图2.1分型面选择图

2.1.2 成型零件结构分析

本套模具的结构是镶块式结构，用推管推出，并且推管也参与塑件的成型的。定模板上面开的两个孔是直接固定定模型腔的，型芯采用台阶式安装的方法进行安装；因为斜推管也参与成型，所以需要和动模型腔进行配合装配，且动模型腔形状特征较多，因此也采用镶块的形式。推管的运动动力由注塑机的打杆推力经

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

过推板运动转化来的斜向动力。如下图2.2所示：

图2.2成型零件的装配简图

2.1.3 成型零件材料的选用

成型零件的材料要求应具备：机械加工性能良好、抛光性能优良、耐磨性和抗疲劳性能好、具有耐腐性能等要求。

所以模具使用T8A优质碳素钢作为成型零件的材料。

2.1.4 成型零件的结构设计

2.1.4.1 定模结构设计

定模是固定在定模安装板上的，它是起固定作用的，考虑到这个产品的结构，故把圆台部分放在定模。如下图2.3所示：

图2.3定模

2.1.4.2 动模和型芯结构设计

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

动模和斜型芯是用来成型塑料制品斜插管和台阶部分的，因斜插管设在台阶分型面下面，所以动模部分设有斜型芯，这也方便塑件的脱模。在这我们采用斜推管推出。如下图2.4所示：

斜型斜推图2.4动模镶块、斜型芯和斜推管

2.1.5 成型零件工作尺寸计算

成型零件的工作尺寸，是用来保证塑料制品的尺寸。模具的制造误差及模具的磨损；塑料成型收缩率的偏差及波动；溢料飞边厚度及其波动；都会影响塑料制品尺寸和公差。

PC材料的收缩率为0.5%～0.8%，且制件精度为MT5。本部分尺寸计算公式参考教材《塑料成形工艺与模具设计》。

可知：

Smax?Smin0.005?0.008 =0.0065 式（6.4） ?22 Scp?2.1.5.1 型腔径向尺寸

根据塑件公差值表型腔径向尺寸分别为：

?76±0.43 ?82±0.5 ?25±0.25 表（3.9） 塑件外形径向尺寸为 LS??

0因此 ?76?0.43?转换???? 76.4382?0.5?转换????82.50?1 ?0.86 ?0 ?25?0.25?转换????25.250?0.5

型腔径向尺寸为LM0Z 根据公式 LM0??Z??z 式（6.6） ?[(1?SCP)LS?x?]0?? 其中x—修正系数，由于塑件精度为MT5，且塑件尺寸较小故取x=0.75

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

?z—制造公差，由于塑件精度为MT5，且塑件尺寸较小故取?z=因此 L??ZM1? 3?[(1?0.065)?76.43?0.75?0.86]0?0.863?0.29=?76.280

校核 ?Smax?Smin?Ls1?Sz

?0.8%?0.5%??76.43?0.860.86??0.65929???0.86 36?13=

?0.33 ?82.290 L??ZM2?[(1?0.065)?82.5?0.75?1]0校核 ?Smax?Smin?Ls1?Sz

?0.8%?0.5%??82.5?11??0.7475???1 36?0.53?0.17=?25.030

L??ZM3?[(1?0.065)?25.25?0.75?0.5]0校核 ?Smax?Smin?Ls1?Sz

?0.8%?0.5%??25.25?0.50.5??0.3256???0.5 362.1.5.2 型腔深度尺寸

根据塑件公差值表型腔深度尺寸分别为：

14±0.26 2±0.2 表（3.9）

塑件外形高度尺寸为HS??

转换因此 14?0.26?转换???14.260?2.20-0。52 2?0.2???-0。4

0型腔深度尺寸为HM0Z 根据公式 HM0??Z??z 式（6.8） ?[(1?SCP)HS?x?]0??其中x—修正系数，由于塑件精度为MT5，且塑件尺寸较小故取x=2/3 ?z—制造公差，由于塑件精度为MT5，且塑件尺寸较小故取?z=

因此 H??ZM1?2?[(1?0.0065)?14.26??0.52]030.523? 3?0.17 =14.010

校核 ?Smax?Smin?Hs?Sz?Sj

?0.8%?0.5%??14.26?0.52?0.22???0.52 37

无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

?2?[(1?0.006)?52.2??0.4]030.43 H??ZM2?0.13 =1.950

校核 ?Smax?Smin?Hs?Sz?Sj

?0.8%?0.5%??2.2?0.4?0.14???0.4 32.1.5.3 型芯径向尺寸

根据塑件公差值表型芯径向尺寸分别为：

?72±0.43 ?20±0.22 ?16±0.19 表（3.9）

塑件孔的径向尺寸为LS0

?0.86?0.44因此 ?72?0.43?转换 ?20?0.22?转换 ???? 71.570????19.780?0.38 ? 16?0.19?转换????15.810??型芯径向尺寸为LM??Z

z根据公式 LM??z?[(1?SCP)LS?x?]0??Z 式（6.7）

00其中x—修正系数，由于塑件精度为MT5，且塑件尺寸较小故取x=0.75 ?z—制造公差，由于塑件精度为MT5，且塑件尺寸较小故取?z=

因此 LM1-?Z?[(1?0.0065)?71.57?0.75?0.86]00.86-30? 3?72.680?0.29

校核 ?Smax?Smin?Ls?Sz?Sc

?0.8%?0.5%??71.57? LM2-?Z00.860.86??0.1645???0.86 36?[(1?0.0065)?19.78?0.75?0.44]00.44?20.240?0.15

-3校核 ?Smax?Smin?Ls?Sz?Sc

?0.8%?0.5%??19.78? LM3-?Z00.440.44??0.28???0.44 36?[(1?0.0065)?15.81?0.75?0.38]00.38?16.200?0.13

-3校核 ?Smax?Smin?Ls?Sz?Sc

?0.8%?0.5%??15.81?0.380.38??0.238???0.38 362.1.5.4 型芯高度尺寸

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

根据塑件公差值表型芯高度尺寸分别为：

50±0.42 14±0.26 表（3.9）

塑件孔高度尺寸为HS??

?0.84?0.52因此 50?0.42?转换 14?0.26?转换 ???49.580???13.7400型芯高度尺寸为HM??Z

根据公式 HM??Z?[(1?SCP)HS?x?]0??Z 式（6.8） 其中x—修正系数，由于塑件精度为MT5，且塑件尺寸较小故取x=2/3 ?z—制造公差，由于塑件精度为MT5，且塑件尺寸较小故取?z=

00? 3)?49.58?因此 HM1-?Z?[(1?0.0065校核 ?Smax?Smin?Hs?Sz?Sj

?0.8%?0.5%??49.58?002?0.84]00.84?50.460?0.28 -330.84?0.43???0.84 3)?13.74? HM2-?Z?[(1?0.0065校核 ?Smax?Smin?Hs?Sz?Sj

?0.8%?0.5%??13.74?2?0.52]00.52?14.180?0.17 -330.52?0.21???0.52 32.2 浇注系统设计

浇注系统对塑件质量影响很大，它是塑料从注射机的喷嘴到模具型腔的进料通道，具有传质，传压和传热的功能。浇注系统一般分为普通流道浇注系统和热流道浇注系统。具体结构见下图2.5所示。

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

图2.5浇注系统

2.2.1 主流道的设计

主流道一般位于模具中处，它将注射机喷嘴射出的塑料熔液流入分流道后进入型腔中。本副模具的主流道截面形状为圆锥形，内锥角4°，内壁表面粗糙度为Ra0.8，因为圆锥形截面以便于熔体的流动和开模时主流道凝料的顺利拔出。如下图2.6所示：

图2.6主流道衬套

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

由于主流道小端入口处与注射机喷嘴会反复撞击接触，是属与易损件，因此对材料要求比较严格，所以主流道一般设计成可更换的主流道衬套形式即浇口套，浇口套一般采用优质碳素钢，这样可以节省模具成本。

因为模具浇道的长度不能大于60mm，因此我采用主流道衬套下沉的形式，最后的固定方式使用定位圈压紧螺钉紧固。具体结构见下图2.7所示：

图2.7 主流道衬套与定位圈

2.2.2 分流道的布置形式

由于本副模具采用一模两腔的形式，并且塑件结构简单。因此，采用如图所示分流道形式，将熔体均匀的充进到各各型腔。如图下图2.8所示：

图2.8分流道

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

2.2.3 分流道的形状

为了便于机械加工及凝料脱模，分流道设置在分型面上定模一侧，截面形状采用加工工艺比较好的半倒圆截面。半倒圆截面对塑料熔体的流动阻力不大。

2.3推出机构的设计

注射成型每个循环中，塑件必须准确无误的从模具的动模中和型芯上脱出，完成脱出塑件的装置称为脱模机构，也常称为推出机构。

2.3.1 梯形推板的推动原理和草图

由于塑件的外部特征中有斜管，因此采用的推管推出机构也必须可以做斜向的运动。但由于之前没有碰到过像这样采用斜向运动的设计理念，然后经过查阅资料同学讨论，再经过自己的理解，我设计出将以前的平推板设计成梯形推板把注塑机的顶杆力转化成我需要的斜向力。通过这个机构我可以让模具实现全自动的生产。结构详见下图2.9所示：

图2.9推出结构

2.3.2 梯形推板的设计要求

梯形推板如果一块板制作会很费材料，因此这里采用三板焊接得到，先备料，在焊接，然后修模配做得到。

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

2.4 排气系统

该套模具是属中型模具，排气量比较多，型腔与型芯安装都有间隙，而且分型面也有一定的间隙，利用这些间隙就能达到排气效果。因此本套模具不单独设计排气槽。

2.5 冷却系统的设计

由于模具在高温成型下，模具会有很高的温度，而温度越高对塑件的成型质量和生产效率影响越大。所以模具上需要添加冷却系统进行温度调节来保证塑件质量。因为水的热容量大，传热系大，成本低，且低于室温的水容易取得，所以冷却水普遍使用。用水冷却即在模具型腔周围或型腔内开设冷却水通道，利用循环水将热量带走。

2.5.1 冷却管道直径

将水流呈湍急状态能更好的达到冷却效果，因此冷却水道直径不能太大。考虑到塑件结构，确定本副模具冷却水道直径为?10。

2.5.2冷却水道的位置

因为动模部分是运动的不好安装冷却系统，而且塑件在定模部分里面，而且定模模板上空出的地方较多，因此此副模具的冷却水道设置在定模部分。如下图2.10所示：

图2.10冷却水道分布

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

2.6 模架与注射机的选择 2.6.1 模架的选择

根据模具型腔布局（一模两腔）及浇注系统的结构形式，又根据相关资料计算得型腔侧壁最小厚度为40mm，再考虑到导柱，导套及连接螺钉布置应占的位置等各方面问题，确定选用模架的基本尺寸为B×L=315×500mm。从选定模架可知，模架外形尺寸为：宽×长×高=400×500×302。

2.6.2 注塑机的选择

2.6.2.1 注射量的计算

通过PRO\\E建模分析，塑件体积约为V1=27.34 cm

33取PC密度为

ρ1=1.2g/cm则塑件质量为： m1=ρ1 V1=1.2×27.34=32.808g

流道凝料的质量m2可按塑件质量的0.8倍来估算。从上述分析中确定为一模两腔，所以注射量为

nm?m12?32.808?0.8?32.808??114.828g 式（2.2） k0.82.6.2.2 塑件和流道凝料的投影面积计算

流道凝料（包括浇口，分流道，主流道凝料）在分型面上的投影面积A2，根据多型腔模的统计分析以及经验计算，A2是每个塑件在分型面上的投影面积A1的0.2?0.5倍，因此可用0.5nA1来进行计算，所以

A=nA1+A2= nA1+0.5 nA1=1.5 nA1 式（2.3）

?82?式中，A1?3.14????5278.34mm2 n代表型腔个数n=2

?2?A?1.5?2?5278.34?15835.02mm2

22.6.2.3 锁模力的计算

锁模力为注射机锁模装置用于夹紧模具的力。所选注射机的锁模力必须大于熔体对模具型腔而产生的胀型力，此胀型力等于塑件和流道系统在分型面上的投影面积与型腔压力的乘积。

即：

F=P×A 式（2.4）

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无锡科技职业学院毕业设计（论文） 斜插座注塑模具结构设计与制造

参考文献

[1]屈华昌. 塑料成型工艺与模具设计[Z].北京：高等教育出版社，2007.4 [2]张中元. 塑料注射模具设计—入门到精通[Z].北京：航空工业出版社，2003.7 [3]史铁梁.模具设计指导[M].北京：机械工业出版社 [4]张荣清.模具制造工艺[M].北京：高等教育出版社.2006 [5]伍先明.塑料模具设计指导[M].北京：国防教育出版社.2006 [6]马金骏.塑料模具设计[M].北京：中国科学技术出版社.1994 [7]杨占尧.塑料模具课程设计[M].北京：化学工业出版社.2001

[8]杨占尧.机械设计手册编委会[M].机械设计手册.北京：机械工业出版社.2004 [9]陈洪. 精密塑料成型.北京：国防工业出版社.1999 [10]奚永生.精密注塑模具设计.北京：中国轻工业出版社.1997 [11]朱锡坤.模具工业.北京：机械工业出版社.2001

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